Air-condensed water chillers and heat pumps YLCA / YLHA 100, 120 and 150

Transcription

1 Air-condensed water chillers and heat pumps YLCA / YLHA 100, 120 and 150 User manual Ref.: N-40291_EN 1110

2 Index Index 1 User manual General description of the unit Models available and capacities Technical specifications Operating instructions µc3 (YLCA / YLHA 100, 120 and 150) Regular maintenance activities for which the user is responsible...25 i

3 1 User manual

4 1 User manual 1.1 General description of the unit 1.1 General description of the unit The YLCA/YLHA units are high-performance air-water chillers and heat pumps using R-410A ecological refrigerant. These units are designed for air conditioning or industrial applications that require cold or hot water. They are silent and compact units, equipped with vertical air discharge axial fans, that can be installed directly outdoors. They are available in two versions: with and without a hydro kit, which includes a buffer tank and a high head pressure pump. The control system of these units is a specially programmed electronic controller to be used on air-water chillers and heat pumps equipped with tandem compressors. Easy to use and safe, these units precision control the water return temperature of the installation, carry out defrost cycles, modulate fan speeds and control compressor, pump and electric heater start-up. By reading the control sensors and safety elements, the controller protects the entire equipment against malfunctions. The system allows connecting the unit to a standard RS485 monitoring network. For further information, please see Operating Instructions. The YLCA/YLHA units are made of proven quality components and manufactured in compliance with standards in force (ISO 9001 certification) Models available and capacities Cool-only model Cooling capacity YLCA 40 YLCA 50 YLCA 60 YLCA 80 YLCA 100 YLCA 120 YLCA ,6 52,1 60,5 77, Heat pump model Cooling capacity Heating capacity YLHA 40 YLHA 50 YLHA 60 YLHA 80 YLHA 100 YLHA 120 YLHA , ,5 72, ,6 52,5 59,6 74, ,6 150 Cooling capacities in kw for 12/7 C water input /output temperature and 35 C ambient temperature. Heating capacities in kw for 40/45 C water input /output temperature and 7 C ambient temperature. 2

5 User manual 1 General description of the unit Technical specifications These units are supplied completely factory-assembled and with all refrigerant tubing and wiring ready for installation on site. After mounting, these units must go through an operational test with water. Refrigerant leaks will also be checked during this process. Sheet casing The units are made of galvanized steel sheeting and anticorrosion nuts and bolts. Panels can be removed for access to internal components. The casing parts are painted with white RAL9001 oven-baked polymerized enamel. Compressors One, two or four hermetic Scroll compressors mounted in tandem on rails and antivibratory supports are used. Compressors are connected for operation with one single cooling circuit. Start-up is carried out by two independent starters. These compressors are equipped with mechanical elements that protect them against high operating temperatures. The crankase heaters operate only when the compressor is inoperative. Water side heat exchanger Comprises a stainless steel plate exchanger, adequately insulated by a layer of closed-cell elastomer foam. Includes an antifreeze heater monitored by the controller. The refrigerant side of said exchanger accepts an operating pressure of 45 bar, whereas the water side accepts 10 bar. When the unit includes a hydro kit, maximum admissible pressure on the water side is 6 bar (adjustment of the tank safety valve). Air side heat exchanger Made up of two notched aluminium blue fin coils and grooved copper tubing mechanically expanded within the fin assembly. Fans Of the axial and low sound level type. Equipped with single-phase motors with IP54 protection. These motors allow speed control by means of a phase cut-out shifter controlled by the unit controller. This allows unit operation at low ambient temperatures (-10 C). On cool only units with an optional low ambient temperature kit can reach 18 C. On heat pumps, the fan will remain inoperative during defrosting. Electrical and control panel Located at the front of the unit, and with IP44 protection. The operating and control components are factory mounted, wired and tested. The door of this control panel is equipped with a locking isolator that turns power supply off. Inside we find the contactors for compressors and the pump, the transformer, magneto-thermal protectors, controller electronic plates, speed control, connecting strip and the keyboard-display with the unit controls. Control keyboard-display This device is accessible through an external leak-tight plastic cover. This is an easy-to-use control with three access levels: direct, user (password) and factory (password). For further information, please see Operating Instructions. Cooling circuit The cool only unit cooling circuit includes: expansion valve, filter-dryer, liquid sight glass, high and low pressure switches, service valves for isolating the condensing unit, and Schrader valves on the high and low sides. The heat pump model also includes, in addition, a four-way valve (energized in summer cycle and during defrosts), retaining valves, a heat cycle expansion valve and a liquid tank. The suction tubing is coated with closed-cell elastomer. 3

6 1 User manual 1.1 General description of the unit Hydro kit (pack) These units include a pack assembled with the components of a hydro kit. This assembly is located within the unit frame and does not increase the footprint of same. It includes the following components: Lined buffer tank and with an antifreeze heater, centrifugal pump, expansion vessel charged with nitrogen at 1.5 bar, safety valve set to 6 bar, water circuit, pressure gauge, two air bleed valves, filling valve and drain valve. Also includes a mesh filter for the water circuit. This filter is supplied loose for installation at the most convenient point. Flow switch Assures sufficient water flow when the unit is in operation. 4

7 User manual 1 General description of the unit 1.1 Options and accessories Units without hydro kit This includes the elements described in the previously mentioned specifications, less the hydro kit (pack). The water circuit includes an air bleed valve. Connections are ready for on-site installation. Two pumps Accessory available with models 50 to 150 with hydro kit. The second pump becomes operative when the magnetothermal protector of the first pump is activated (models 50, 60 and 80), or through the controller program (models 100, 120 and 150). Water filter Supplied as a standard element on units including the hydro kit. Stainless steel mesh with 1 mm. diameter perforations. Optional on units not including the hydro kit. The warranty of the unit will not be valid if a water filter has not been installed. Remote control Wall-mounted remote control unit with keyboard for cool /heat and ON /OFF functions. Includes power supply, alarm and cool /heat LEDs. Maximum cable length: 50 m. Remote terminal For total access and control of the system by means of the display and buttons. It allows for selection of cool, heat and off functions. Operating parameters can also be modified and the system can also be supervised. Can be installed at a maximum distance of 1040 m. BMS connections By means of a serial board, it is possible to connect the system to a standard RS485 monitoring network. Low noise level units (LN) Include anti-noise covers mounted on the compressors and sound isolating plates, covering the compressor chamber. Soft starter For the soft motor start. Specially designed for Scroll compressors. (Maximum outdoor temperature: 50 ). Protecting grids To protect the coils from possible impacts. Made of steel rods and painted with oven baked polymerized white enamel (RAL9001). 5

8 1 User manual 1.1 General description of the unit Antivibratory supports Whenever necessary to reduce vibrations and noise produced by the unit to a maximum, a set of steel spring antivibratory supports can be used. These should be installed between the chassis support of the unit and the base or floor on which it is to sit. This base must be solid and dimensioned in accordance with the load to be supported. The antivibratory support accessory for models YL CA/YLHA 40, 50 and 60 includes 4 units, whereas for models YLCA/YLHA 80, 100, 120 and 150 includes 6. These spring supports should be distributed and fastened in the drilled holes at the base of the chiller, the location of which is detailed in the General Dimensions section. 6

9 User manual 1 General description of the unit Operating instructions µc3 (YLCA / YLHA 100, 120 and 150) This is a specially programmed controller for air-water chillers and heat pumps with four capacity stages. These are divided into two independent cooling circuits equipped with two tandems that act upon a common water circuit. Both systems are equipped with two fans each, the speed of which is controlled by pressure sensors. The controller operates through the following intakes and outlets. Digital inputs ID1 J1/8 ID2 J1/1 ID3 J1/9 ID4 J1/2 ID5 J1/10 ID6 J4/8 ID7 J4/1 ID8 J4/9 General protection (PG) Flow switch (FS) Remote ON/OFF (ROO) Pump protector No. 1 (Q5) Low-pressure switch circuit 1 (LP1) High-pressure switch circuit 1 (HP1) Thermal protector compressor 1 (THPC1) Thermal protector compressor 2 (THPC2) ID9 J4/2 Thermal protector circuit 1 fans (THPF 1-2) ID10 J4/10 ID11 J7/6 ID12 J7/1 ID13 J7/8 Low-pressure switch circuit 2 (LP2) High-pressure switch circuit 2 (HP2) Thermal protector compressor 3 (THPC3) Thermal protector compressor 4 (THPC4) ID14 J7/3 Thermal protector circuit 2 fans (THPF 3-4) ID15 J7/9 ID18 J7/5 Remote COOL/HEAT (RCH) Pump protector No. 2 (Q6) Digital outputs N01/C1-2 Compressor 1 circuit 1 (K1) N02/C1-2 Compressor 2 circuit 1 (K2) N05/C5 Pump 1 N06/C6-7 Compressor 3 circuit 2 (K3) N07/C6-7 Compressor 4 circuit 2 (K4) N08/C8-9 Pump 2 N010/C10 Alarm N011/C11-12 Antifreeze heater circuit 1-2 N012/C11-12 Back-up heater N013/C way valve circuit 1 (V4V1) N014/C way valve circuit 2 (V4V2) 7

10 1 User manual 1.1 General description of the unit Analogue inputs B3 J2 Coil pressure circuit 1 B4 J3 Coil pressure circuit 2 B5 J4/13 Water temperature at exchanger inlet B6 J4/12 Water temperature at exchanger outlet Analogue outputs Y3 Y4 Circuit 1 fan speed control (PWM) Circuit 2 fan speed control (PWM) 8

11 User manual 1 General description of the unit 1.1 System components The system is made up of the following basic components: Touch screen µc3 controller Fan speed controllers (FSC1 and FSC2) Pressure sensors (B3 and B4) NTC sensors (B5 and B6) Touch screen This consists of a screen and six keys with the following functions: Alarm 2- Programming 1- Esc (Escape) Up 3- Enter 4- Down 5- The following functions can be selected from this screen: ON/OFF COLD/HEAT Read the unit status Access the configuration menus (by means of a password) Read the alarm messages and reset these alarms Read operating pressures and temperatures etc... µc3 controller This contains the unit software and the entire digital and analogue input and output connector system. This module is also equipped with connectors the program download key and the serial communication connection to an RS485 monitoring system. 9

12 1 User manual 1.1 General description of the unit Sensors and probes Pressure sensors (B3 and B4) One for each cooling circuit and connector to the coil collectors. They provide information to the system for fan speed adjustment in the summer and winter cycles, management of defrosts in the heat pumps, prevent and lockout functions of the system by excessively high pressure. NTC probes(b5 and B6) B5- For the detection and control of water inlet temperature (cool only and heat pump units). B6- For the detection of water outlet temperature. It provides information for antifreeze protection and control of the antifreeze and backup heaters. If required, allows controlling water temperature at the heat exchanger discharge 10

13 User manual 1 General description of the unit 1.1 General diagram, (YLCA / YLHA 100,120 and 150) A Keyboard display terminal U Water outlet B Programme download key V Water inlet D/J/C/I Comp. 1/ Comp. 2 / Comp. 3 / Comp. 4 X Fan protection 12 E/H Pump 1/ Pump 2 Y/A1/G1/ I1 Protection comp. 1 / Protection comp. 2 / Protection comp. 3 / Protection comp. 4 K RS485 serial connection Z/H1 HP1 / HP2 (High-pressure switch) L Phase (board power supply) C1 Fan 3.4 M General protection D1 Fan 1.2 N Neutral (board power supply) F1 Fan protection 3.4 O Remote ON / OFF J1 Remote COOL / HEAT P2/B1 LP1 / LP2 (Low-pressure switch) K1 4-way valve, circuit 1 Q/E1 Pump 1 protection / Pump 2 protection M1 4-way valve, circuit 2 R Flow switch O1 Antifreeze heater S/T Circuit 1 pressure sensor / Circuit 2 pressure sensor P1 Back-up heater 11

14 1 User manual 1.1 General description of the unit Start-up About 45 seconds after powering the unit, the start-up display is activated. Default language: English. 1st Display. START-UP (information on water temperature/unit status) Water inlet temperature Water outlet temperature Unit status (ON/OFF) Press "down" to access the second display. 2nd Display. STATUS AND OPERATING MODE SELECTION Status selection ON/OFF (with ENTER, Up and Down). On the heat pump units, select the COOL/HEAT operating mode (with ENTER, Up and Down). Press ESC to return to the 1st display. SYSTEM CONFIGURATION (For authorised servicing personnel only) 3rd Display. ENTER PASSWORD The 3rd Enter password display is accessed by pressing Up from the 1st display (Start-up), or Down from the 2nd display (Status / operating mode selection) 1 From the Enter password display, press ENTER. 2 Enter the password using the Up key. 3 Press ENTER to access the 4th Menu display. 4th Display. MENU From this display we can access a set of submenus that provide information on the unit or allow for its operating parameters to be configured. These submenus are as follows: -/- Sensors Sensors config. -A- Antifreeze Antifreeze -B- Input/output Input/output -c- Compressors Comps. conf. -d- Defrost Defrost -F- Condensation (fans) Condensation -H- Unit configuration Unit config. -P- Alarms Alarm settings -r- Temperature control Control param. -Fr- Software version / language selection Soft. version -t- Time (not available) Time config. To enter a submenu: 1 Select it using the Up or Down key and then activate it using the ENTER key 2 Once the parameters are set with the ENTER, Up and Down keys, press Prg to confirm the modification and return to the MENU display. 3 To exit the MENU display, press the Esc key. 12

15 User manual 1 General description of the unit 1.1 -/- Configuration of sensors Description Range Units Value Sensor B3 calibration. Coil pressure circuit 1-9,9/9,9 bar 0 Sensor B4 calibration. Coil pressure circuit 2-9,9/9,9 bar 0 Sensor B5 calibration. Inlet water temp. to exchanger. -9,9/9,9 K 0 Sensor B6 calibration. Outlet water temp. to exchanger. -9,9/9,9 K 0 Sensor B7 calibration. Outdoor temperature -9,9/9,9 K 0 Sensor B8 calibration. Dynamic set point -9,9/9,9 % 0 Enabling sensor B1 YES / NO - NO Enabling sensor B2 YES / NO - NO Enabling sensor B3. Coil pressure circuit 1 YES / NO - YES Enabling sensor B4. Coil pressure circuit 2 YES / NO - YES Enabling sensor B5. Inlet water temp. to exchanger. YES / NO - YES Enabling sensor B6. Outlet water temp. to exchanger. YES / NO - YES Enabling sensor B7 YES / NO - NO Enabling sensor B8 YES / NO - NO Enabling sensor B9. YES / NO - NO Enabling sensor B10. YES / NO - NO Sensor B3 configuration. Minimum value -30/150 bar 0 Sensor B3 configuration. Maximum value -30/151 bar 45 Sensor B4 configuration. Minimum value -30/152 bar 0 Sensor B4 configuration. Maximum value -30/153 bar 45 -A- Antifreeze Description Range Units Value Antifreeze alarm set point -99,9/99,9 C 3 Antifreeze alarm set point differential 99,9 K 5 Lower antifreeze alarm set point limit -99,9/99,9 C 3 Upper antifreeze alarm set point limit -99,9/99,9 C 5 Antifreeze alarm reset MANUAL AUTOMATIC - MANUAL Antifreeze alarm delay (If automatic reset has been selected) 0/540 Minutes 0 Antifreeze heater trigger set point -99,9/99,9 C 3 Antifreeze heater trigger set point differential -99,9/99,9 K 2 Auxiliary heater trigger set point (winter cycle) -99,9/99,9 C 25 Auxiliary heater trigger set point differential (winter cycle) -99,9/99,9 K 5 Auxiliary heater trigger delay 0/60 Minutes 15 Automatic enabling of the frost protection system with the unit OFF DISABLED HEATER AND PUMP HEATER AND UNIT HEATER - HEATER 13

16 1 User manual 1.1 General description of the unit -C- Compressor configuration Description Range Units Value Min. operating time of a compressor 0 / 9999 Seconds 120 Min. stoppage time of a compressor 0 / 9999 Seconds 60 Start-up time between different compressors 0 / 9999 Seconds 3 Start-up time of one compressor 0 / 9999 Seconds 300 Start-up time between pump and compressor 0 / 999 Seconds 20 Stoppage time between compressor and pump 0 / 999 Seconds 20 Pump 1 operating hours Pump 2 operating hours Compressor 1 operating hours Compressor 2 operating hours Compressor 3 operating hours Compressor 4 operating hours Operating hours for pump maintenance alarm 1000 / Hours 0 x 1000 Operating hours for compressor 1 / circuit 1 maintenance alarm 1000 / Hours 0x 1000 Operating hours for compressor 2 / circuit 1 maintenance alarm 1000 / Hours 0x 1000 Operating hours for compressor 1 / circuit 2 maintenance alarm 1000 / Hours 0x 1000 Operating hours for compressor 2 / circuit 2 maintenance alarm 1000 / Hours 0x 1000 Tandem compressor rotation time Minutes 20 Enabling of compressors C 1/1, C 2/1, C 1/2, C 2/2 YES / NO YES Forced manual compressor operations YES / NO NO -d- Defrost When a defrost cycle is being carried out, the message DEFROST REQ appears on the start-up display. Description Range Units Value Pressure temp. Defrost sensor selection - Pressure Pressure switch Separate Separate or simultaneous defrost (contemporaneous) - Separate Simultaneous Time End defrost by interval of - Temp. / Pressure Temp. / Pressure Defrost start pressure -99,8 / 99,9 bar 5,8 Defrost end pressure -99,8 / 99,9 bar 26 Defrost call delay 1 / Seconds 180 Max. defrost time 1 / Seconds 420 Min. defrost time 1 / Seconds 0 Timing between defrosts of a single circuit 1 / Seconds 1800 Timing between defrosts of different circuits 1 / Seconds 300 Forced compressor stoppage time at start and end of defrost 0 / 999 Seconds 0 4-way valve inversion delay 0 / 999 Seconds 0 Enabled Manual defrost - Disabled Disabled 14

17 User manual 1 General description of the unit 1.1 -F- Condensation (fans) Description Range Units Value Type of fan control Temp. pressure ON/OFF - Pressure No. of condensers Fans - Control device Inverter Inverter - Power supply frequency 50 / 60 Hz 50 PWM max. triac cut-off 0 / 100 % 92 PWM min. triac cut-off 0 / 100 % 35 Triac impulse duration 0 / 10 ms 2 Condensing pressure in summer cycle 0 / 99,9 bar 21 Condensing pressure differential in summer cycle 0 / 99,9 bar 5 Evaporating pressure in winter cycle 0 / 99,9 bar 9,5 Evaporating pressure differential in summer cycle 0 / 99,9 bar 1,5 Min. fan speed differential -99,9 / 99,9 bar 3 Max. inverter speed 0 / 10 V 10 Min. inverter speed 0 / 10 V 1 Inverter speed-up time 0 / 999 Seconds 5 Prevent function activation (HP) YES / NO - YES Pressure Selection of sensor for HP prevention - Pressure Temperature HP prevention pressure -99,9 / 99,9 bar 38 HP prevention pressure differential 0 / 99,9 bar 4 LP prevention pressure -99,9 / 99,9 bar 3 LP prevention pressure differential 0 / 99,9 bar 1,5 Fan OFF Fan management in case of sensor failure Fan OFF Fan ON and Compressor ON Prevent function timing 0 / 99 Seconds 0 15

18 1 User manual 1.1 General description of the unit -H- Unit configuration Description Range Units Value Unit type (COOLER) 3 (HEAT PUMP) Number of compressors/circuits - 4 / 2 Compressor rotation LIFO FIFO PERSONALISED TIME - FIFO No. of evaporators Driver number (EVD400) Cycle inversion valve logic NO / NC - NC No. of pumps Pump rotation Pump operation START-UP TIME ON WITH COMP. ON ALWAYS OFF ALWAYS ON SAFETY ON/ OFF 1 (SINGLE PUMP) 2 (TWO-PUMP ACCESSORY) - TIME ALWAYS ON No. of hours for pump rotation Hours 12 ON/OFF digital input activation YES / NO - NO WINTER/SUMMER digital input activation YES / NO - NO ON/OFF activation with Monitor YES / NO - NO WINTER/SUMMER activation with Monitor YES / NO - NO WINTER/SUMMER operation inversion delay Seconds 10 Monitoring protocol Selection of communication speed CAREL GSM MODEM ANALOGUE MODEM RS 232 LONWORKS MODBUS CAREL Bauds Monitoring ID number Selection of language at start-up YES / NO - YES Restore default values (Warning!) YES / NO - NO 16

19 User manual 1 General description of the unit 1.1 -B- Inputs/Outputs Description Range Units Value Analogue input 3. Coil pressure circuit 1 (B3) bar INSTANT READ OUT Analogue input 4. Coil pressure circuit 2 (B4) bar INSTANT READ OUT Analogue input 5. Inlet water temperature (B5) C INSTANT READ OUT Analogue input 6. Outlet water temperature (B6) C Digital input 1. External alarm O/C Digital input 2. Flow switch O/C Digital input 3. Remote ON/OFF O/C Digital input 4. Pump 1 protector O/C Digital input 5. Low-pressure switch circuit 1 O/C Digital input 6. High-pressure switch circuit 1 O/C Digital input 7. Thermal protector compressor 1 circuit 1 O/C Digital input 8. Thermal protector compressor 2 circuit 1 O/C Digital input 9. Fan 1-2 protectors circuit 1 O/C Digital input 10. Low-pressure switch circuit 2 O/C Digital input 11. High-pressure switch circuit 2 O/C Digital input 12. Thermal protector compressor 3 circuit 2 O/C Digital input 13. Thermal protector compressor 4 circuit 2 O/C Digital input 14. Fan 3-4 protector circuit 2 O/C Digital input 15. Remote COOL/HEAT O/C Digital input 16. Not used Digital input 17. Not used Digital input 18. Pump 2 protector Digital output 1. Compressor 1 circuit 1 O/C Digital output 2. Compressor 2 circuit 1 O/C Digital output 3. (Not used) Digital output 4. (Not used) Digital output 5. Pump 1 O/C Digital output 6. Compressor 3 circuit 2 O/C Digital output 7. Compressor 4 circuit 2 O/C Digital output 8. (Not used) Digital output 9. (Not used) Digital output 10. External alarm / fuse failure O/C Digital output 11. Antifreeze heater O/C Digital output 12. Backup heater O/C Digital output way valve circuit 1 O/C Digital output way valve circuit 2 O/C 17

20 1 User manual 1.1 General description of the unit -P- Alarms Description Range Units Value High-pressure alarm set point (transducer B3; B4) 0 / 99,9 bar 41 High-pressure alarm differential (transducer B3; B4) 0 / 99,9 bar 10 Summer low-pressure alarm 0 / 99,9 bar 3 Winter low-pressure alarm 0 / 99,9 bar 2 Defrost low-pressure alarm 0 / 99,9 bar 1 Low-pressure differential 0 / 99,9 bar 1 Low-pressure alarm delay on cold cycle start-up Seconds 60 Low-pressure alarm delay on heat cycle and defrost Seconds 0 Water flow control (flow switch) alarm delay on start-up Seconds 20 Water flow control (flow switch) alarm delay on operating Seconds 5 Number of automatic reset alarm stoppages Maximum period for automatic reset alarms 0 99 Minutes 60 Alarm selection with automatic reset: compressor thermal breaker Alarm selection with automatic reset: fan thermal breaker Alarm selection with automatic reset: low-pressure switch Alarm selection with automatic reset: high-pressure switch AUTOMATIC / MANUAL AUTOMATIC / MANUAL AUTOMATIC / MANUAL AUTOMATIC / MANUAL AUTOMATIC AUTOMATIC AUTOMATIC AUTOMATIC -r- Control When this submenu is activated, the dynamic set point temperature appears (if this function is enabled). Press Down to access the configuration menu. Description Range Units Value Set point in COOL C 12 Set point in HEAT C 40 Temperature control adjustment range K 3 COOL set point lower limit C 6 COOL set point upper limit C 20 HEAT set point lower limit C 25 HEAT set point upper limit C 45 Temperature setting type INPUT / OUTPUT - INPUT Setting type with input sensor PROPORTIONAL / P+I PROPORTIONAL Integration time in each adjustment P+I 0 / 9999 Seconds 600 Max. increase time of call (output adjustment) 0 / 9999 Seconds 20 Min. increase time of call (output adjustment) 0 / 9999 Seconds 20 Max. decrease time of call (output adjustment) 0 / 9999 Seconds 10 Min. decrease time of call (output adjustment) 0 / 9999 Seconds 10 Temp. differential in which increase and decrease times vary (output adjustment) -99,9 / 99,9 C 2 Forced stoppage in COOL cycle (output adjustment) -99,9 / 99,9 C 5 Forced stoppage in HEAT cycle (output adjustment) -99,9 / 99,9 C 47 18

21 User manual 1 General description of the unit 1.1 µc3 functions F-r. Software version / Language selection Read out of the µc3 software version and update date. The Up, Down and Enter keys select the language: English or Italian. Temperature control Two different modes (Control Menu): 1 Adjustment by water temperature at the heat exchanger inlet (sensor B5). This control carries out a proportional type adjustment based on a set point and a proportional band distributed over 4 stages. This is the controller default type. It is also possible to carry out a proportional and integral adjustment. In this case, said function must be enabled and the integration time set (CONTROL MENU). Control sensor: B5 ((inlet water temperature to heat exchanger). Parameters to be used: Set point. Proportional band for inlet adjustment. Type of adjustment (Proportional or Proportional + Integral) Integration time (if the Proportional + Integral adjustment has been enabled). Control outputs: N1, N2, N6 and N7 (compressor contactors). Description of the operation: Temperature control depends upon the value measured by the sensor located at the water inlet to the heat exchanger. It follows a proportional logic in which the proportional band is subdivided into four equal stages that give way to on/off functions of the compressors. In Proportional + Integral operation behaviour is similar, but affected by al algorithm that takes time into account (integration time parameter). STPM RBM Set point: A = Cool B = Heat Control band EWT C1, C2, C3, C4 Exchanger inlet temperature Compressor stages 2 Adjustment by water temperature at the outlet of the heat exchanger. Thermostatic control is based on the temperature value detected by sensor B6. Based on the set point value (STPM) and the control base (RBM), it defines a neutral temperature zone (NZ). The temperature values comprised between the set point and the set point plus the band (STP Temperature STPM + RBM) do not cause the on/off function of the compressors. Temperature values above the set point plus the band (Temperature > STPM + RBM) cause compressor operation. Temperature values below the set point (Temperature < STPM) cause compressor stoppage. The on/off process of the compressors is controlled by a variable delay time. Based on the time differential calculated as the delay, and in accordance with the temperature detected by sensor B6, this control will modulate the on/off process of the compressors. If set to 0, minimum delay time at increase/decrease of the power demand, this function is disabled. There is a different temperature differential for the cool/heat cycles (below or above...), as of which there is an unconditional off of the devices installed to avoid excessive cool/heat cycles. 19

22 1 User manual 1.1 General description of the unit STP M Set point TVD Phase input/output time variation differential RBM Control band HTON NZ Neutral zone LTON EOW T DonZ Water temperature at exchanger outlet Compressor ON zone HT OFF LT OFF DoffZ Compressor off zone t Time Stage activation maximum time delay Stage activation minimum time delay Stage deactivation maximum time delay Stage deactivation minimum time delay Compressor rotation The controller provides a FIFO type rotation in which the first compressor to go on will also be the first to go off. Start-up sequence: C1, C2, C3, C4. Stoppage sequence: C1, C2, C3, C4. HP prevent When this function is enabled, the controller attempts to avoid the blockage of the unit due to excessively high pressure. When said pressure reaches a preestablished value near the off pressure, the controller speeds up the fans to a maximum (if in cool cycle), or slows them down to a minimum (if in heat cycle). If the operating pressure continues getting close to the HP Prevent pressure, the controller turns off a compressor in the tandem of the affected circuit. The parameters of said function are accessed from the CONDENSATION menu. Defrost cycle If the evaporating pressure of one of the systems remains below the value set for starting defrost during an accumulated period of time equal to the period established as the delay between defrosts, simultaneous defrost of all unit coils is started. The cycle ends once the pressure set as end defrost is reached, or at the end of the time period set as maximum duration of the cycle. The defrost sequence is as follows: 1 Compressor are turned off 2 After 15 sec., the 4-way valves are inverted 3 After 45 sec., the compressors start with the fans off 4 Once defrost is completed, the compressors stop 5 After 15 sec., the 4-way valves are inverted 6 After 45 sec., the compressors and the fans start Control sensors: Pressure transducers B3 and B4. Parameters used: Simultaneous defrost. Defrost start pressure Defrost end pressure Defrost call delay Max. defrost time Min. defrost time Forced compressor stoppage time due to cycle inversion 4-way valve inversion delay Affected outputs: Compressors (N1, N2, N3 and N4) 20

23 User manual 1 General description of the unit way valves (N13 and N14) Fans (Y3 and Y4) DefrOff Defrost end pressure DefrAct Defrost active DefrOn Defrost start pressure t Time t Partial times remaining in defrost start pressure zone Antifreeze protection If the B6 temperature sensor (water outlet) detects a temperature below the antifreeze set temperature, the unit is blocked and in a state of alarm (manual reset). Simultaneously, the protecting heaters of the plate heat exchanger (output N11) are connected. If the unit includes a hydro kit, the accumulator tank protection heaters will also be activated. Said heaters will turn off when the D6 sensor detects a temperature equal to the antifreeze temperature, plus a preestablished differential. The antifreeze system will operate despite the status and mode of the unit. Antifreeze protection can also include start-up of the pump and unit (see parameters in theanti FREEZE menu). Back-up heater If following a preestablished time period after unit start-up in heat mode the water outlet temperature detected by B6 does not reach the minimum value, backup heater output (N12) is activated. Once the water temperature has reached said value, plus a preestablished differential, said output will be deactivated (see parameters in the ANTIFREEZE menu). Remote ON/OFF A digital ON/OFF remote input can be installed between terminals ID3-G0, and enabled with the corresponding parameters of the H unit config menu. If the contact is open, the unit will remain OFF. If the contact is closed, the unit will remain ON. If the unit is OFF due to said digital input, a message appears on the display indicating as such. The unit will remain OFF whenever any of its inputs: user keyboard, digital or monitoring input are OFF. Remote COOL / HEAT A digital COOL/HEAT remote input can be installed between terminals ID15-G0, and enabled with the corresponding parameters of the H menu. If the contact is open, the unit will remain in HEAT cycle. If the contact is closed, the unit will remain in COOL cycle. If the digital COOL/HEAT input is enabled, said selection cannot be made from the user's or supervisor's keyboard. To change the cycle, either from the digital input, the user's keyboard or the supervisor's keyboard, the unit must be OFF. If the digital COOL/HEAT input is not enabled, said function can be carried out indifferently from the user's or supervisor's keyboard. 21

24 1 User manual 1.1 General description of the unit Second pump A second pump can be enabled by means of the -H-unit config menu. To do this, install the contactor (pump ) between terminals N8-N, and the corresponding protector (contact NC) between terminals Dl18-G0. This second pump will operate alternately with the first pump, taking into account the number of operating hours or start-up cycles. In the case of a protector failure of one of the two pumps, the available pump will activate immediately. Download key The central C3 module has a connector (J11) for connection of a download key (PSOPZKEYAO) with the unit operational programme. Serial connection for monitoring Controller C3 allows connecting to a monitoring system using an RS485 serial board. It is possible to configure and enable this function from the -H- unit config menu. The system has two monitoring protocols: Carel and Modbus. AUTO-RESTART When the unit is turned off by a power shortage, and once this has been restored, the unit retains the same operating mode and status that was present before the shortage. Alarm system When an alarm is triggered, the red key on the upper left corner of the user's keyboard-display lights up. By pressing this key, the cause of the alarm appears on the display. Then press the Up or Down keys to check for further causes of the failure, which will appear on the display successively. When the alarms are automatically reset, unit operations are restored once the causes of the alarm have disappeared. If the failure is manually reset, and once its cause has disappeared, the Alarm key must be pressed to restore unit operations. The press the Esc button to return to the initial display. 22

25 User manual 1 General description of the unit 1.1 Alarm table Description Input Off circ.1 Off circ.2 Off fan Off pump Off sys Reset Delay Notes Serious alarm FC, PG ID1 X MANUAL - Antifreeze alarm B6 X X X X X MANUAL - Pump 1 heat switch Q5 ID4 X X X X X MANUAL - Pump 2 heat switch Q6 ID18 X X X X X MANUAL - PDW flow switch, FS ID2 X X X X X MANUAL Selectable Circ. 1 fan heat switches THPF1, THPF2 Circ. 2 fan heat switches THPF3, THPF4 Compressor 1 A1 heat switches (YCSA/LCA 150, YCSA-H/BRAW 150) Compressor 2 A2 heat switches (YCSA/LCA 150, YCSA-H/BRAW 150) Compressor 3 A3 heat switches (YCSA/LCA 150, YCSA-H/BRAW 150) Compressor 4 A4 heat switches (YCSA/LCA 150, YCSA-H/BRAW 150) Circ. 1 high-pressure switch HP1 Circ. 2 high-pressure switch HP2 Circ. 1 high-pressure switch LP1 Circ. 2 high-pressure switch LP2 Circ. 1 high-pressure switch by transducer Circ. 2 high-pressure switch by transducer ID9 X - Circ ID14 - X Circ ID7 Comp ID8 Comp ID12 - Comp ID13 - Comp ID6 X - Circ ID11 - X Circ ID5 X - Circ ID10 - X Circ AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL AUTO/ MANUAL 1st fault within 60' interval, automatic reset 2nd fault within 60' interval, automatic reset 3rd fault within 60' interval, automatic reset 4th fault within 60' interval, automatic reset 5th fault within 60' interval, automatic reset 6th fault within 60' interval, automatic reset general Phase control protection The pump can be running in OFF mode. See antifreeza menu. If available, pump 1 starts up. If not, the entire system stops. If available, pump 1 starts up. If not, the entire system stops. Delays on start-up and while operating 2nd fault within 60' interval, manual reset 2nd fault within 60' interval, manual reset 3rd fault within 60' interval, manual reset 4th fault within 60' interval, manual reset 5th fault within 60' interval, manual reset 6th fault within 60' interval, manual reset manual reset manual reset manual reset manual reset B3 X - Circ MANUAL manual reset B4 - X Circ MANUAL manual reset B3 sensor faulty B3 X X X X X MANUAL 60' B4 sensor faulty B4 X X X X X MANUAL 60' B5 sensor faulty B5 MANUAL 60' B6 sensor faulty B6 MANUAL 60' B7 sensor faulty B7 MANUAL 60' B8 sensor faulty B8 MANUAL 60' Pump 1 maintenance System MANUAL Pump 2 maintenance System MANUAL Compressor 1 maintenance Compressor 2 maintenance System MANUAL System MANUAL Set period in Compressor menu Set period in Compressor menu Set period in Compressor menu Set period in Compressor menu 23

26 1 User manual 1.1 General description of the unit Description Input Off circ.1 Off circ.2 Off fan Off pump Off sys Reset Delay Notes Compressor 3 maintenance Compressor 4 maintenance System MANUAL System MANUAL Set period in Compressor menu Set period in Compressor menu 24

27 User manual 1 General description of the unit 1.1 Temperature/resistance properties of NTC control sensors (10kOhms) Temperature [ C] Resistance [kohms] Temperature [ C] Resistance [kohms] Temperature [ C] Resistance [kohms] Temperature [ C] Resistance [kohms] Temperature [ C] , , , ,8 86 1, , , , , , , , , , , , , , , , , ,2 56 3, , , , , , , , , , , , ,8-9 40, , , ,8-8 38, , , , ,7-7 37, , , , ,4-6 35, , , , ,3-5 33, , , , ,9-4 32, , , , ,1-3 31, , , , ,8-2 29, , , , , , , , ,6 0 27, , , , ,7 1 26, , , , ,2 2 25, , , , ,1 3 23, , , , ,3 4 22, , , , ,7 5 22, , , , ,4 6 21, , , , , ,2 41 5, , , ,8 8 19, , , , ,7 43 5, , , , , , , , , , , , , , , ,9 47 4, , , , , , , , ,3 83 1, , , , , , , , ,45 Resistance [kohms] Regular maintenance activities for which the user is responsible Maintenance Schedule The air conditioning unit is designed to require as little maintenance as possible. Nevertheless, to ensure smooth operations with a minimal use of electricity, a long working life and compliance with the regulations of each country, regular maintenance inspections must be made. Johnson Controls Inc. shall not be considered responsible for any damage caused by improper maintenance of the unit, which includes anything inconsistent with that described in this document or others specifically provided with the unit. To make them easier, maintenance tasks have been grouped by time intervals in a series of tables. Maintenance responsibilities of the user, see on page

28 1 User manual 1.1 General description of the unit Maintenance responsibilities of the user Like any other machine, the HVAC unit requires regular maintenance, as the wear to which some of its parts are subjected can effect its mechanical reliability and the safety of those responsible for its maintenance. In compliance with current regulations, the unit must be regularly inspected and the results recorded on the forms provided by the Labour and Health Authorities of the country where the HVAC unit is installed. Users cannot access this form to perform maintenance and upkeep tasks on the unit. There is no intent for the user to perform any maintenance tasks on the HVAC unit. D A N G E R It is strictly prohibited for the user to carry out any maintenance or upkeep tasks on the HVAC unit. This appliance is not destined for use by people (including children) with limited physical, sensorial or mental capacities, or without adequate experience or knowledge, unless they have received instructions or been supervised in the use of the appliance by an individual responsible for their safety. Children must be supervised at all times to ensure that they do not play with the appliance. Only trained Johnson Controls Inc. personnel with the necessary means and tools may carry out maintenance and upkeep work on the unit. Trained personnel must be aware of the health and safety regulations and procedures applicable to HVAC units. They should also be aware of general procedures and those applying specifically to this unit. Contact a Johnson Controls Inc. Authorised Technical Assistance Service for scheduled maintenance on this unit. PRODUCT DISPOSAL According to Directive 2002/96/EC of the European Parliament and of the Council of 27 January 2003, the presence of the symbol on the product or in the documents included with the product indicates that this product is classified, according to current law, as an electrical and electronic device and, therefore, this product cannot be dealt with at the end of its working life as domestic or urban waste. The product must be taken to collection points for the recycling of waste electrical and electronic equipment. The appropriate management, reuse, assessment and recycling of these products protect human health and the environment. 26